Vibratory separator screens

ABSTRACT

A screen assembly which, in at least certain aspects, has at least one wire mesh screen formed with undulating mesh material having a series of ridges spaced apart by a series of valleys, a corrugated perforated plate with an undulating shape corresponding to the undulating mesh material of the at least one wire mesh screen, the at least one wire mesh screen on the corrugated perforated plate, a series of spaced apart rods all of which are in one plane, the corrugated perforated plate mounted on the rods of the series of spaced apart rods, and each rod having a length and independent of and not connected to the other rods along its length by any member in the same plane as the rods, each rod having two spaced apart ends.

RELATED APPLICATIONS

This is a continuation-in-part of U.S. Ser. No. 09/183,005 filed Oct.30, 1998 which is a continuation-in-part of U.S. application Ser. No.09/090,554 filed Jun. 4, 1998 entitled “Vibratory Separator Screen”which is a continuation-in-part of U.S. application Ser. No. 08/895,976filed Jul. 17, 1997 entitled “Screen For Vibratory Shaker” which is acontinuation-in-part of U.S. application Ser. No. 08/786,515 filed Jan.21, 1997 entitled “Screen For Shale Shaker” and of U.S. application Ser.No. 08/598,566 filed Feb. 12, 1996 entitled “Screen For VibratingSeparator.” U.S. application Ser. No. 08/786,515 is a continuation inpart of the following co-owned applications and Patents: U.S. Ser. No.29/048,575 filed Jan. 4, 1996, now U.S. Pat. No. D 377,656 issued Jan.28, 1997 which is a continuation of U.S. Ser. No. 29/014,571, filed Oct.25, 1993 now U.S. Pat. No. D 366,040 issued on Jan. 9, 1996 which is acontinuation-in-part of U.S. applications: Ser. No. 08/056,123 filedApr. 30, 1993, now U.S. Pat. No. 5,385,669 issued on Jan 31, 1995; andSer. No. 08/105,696 filed Aug. 12, 1993, now U.S. Pat. No. 5,392,925issued on Feb. 28, 1995; U.S. Ser. No. 08/504,495 filed Jul. 20, 1995entitled “Shale Shaker Screen;” U.S. Ser. No. 08/598,566 filed Feb. 12,1996 entitled “Screen For Vibrating Separator” which is acontinuation-in-part of U.S. Ser. No. 08/220,101 filed Mar. 30, 1994 nowU.S. Pat. No. 5,490,598 issued Feb. 13, 1996. This is acontinuation-in-part of U.S. application Ser. No. 08/504,495 filed Jul.20, 1995 (U.S. Pat. No. 5,598,930; Feb. 4, 1996) and Ser. No.08/220,101; Mar. 30, 1994 (U.S. Pat. No. 5,490,598; Feb. 13, 1996). Allof these related applications and patents are incorporated herein intheir entirety for all purposes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to screens for vibratory shakers,screens for classifying and/or filtering material, such screens with oneor more ramped portions, and screens with individual screen modules,ramps, and/or plugs, and methods of screen repair and assembly.

2. Description of Related Art

The related art section of each of the above-identified applications isincorporated here fully by reference.

SUMMARY OF THE PRESENT INVENTION

The present invention discloses a screen assembly for a vibratoryseparator or shale shaker, the screen assembly having at least one wiremesh screen formed with undulating mesh material having a series ofridges spaced apart by a series of valleys, an optional perforated platewith an undulating shape corresponding to the undulating mesh materialof the at least one wire mesh screen, and a series of spaced apart rods,the corrugated perforated plate mounted on the rods of the series ofspaced apart rods. In other aspects, the present invention discloses ascreen assembly for a vibratory separator or shale shaker, the screenassembly having at least one wire mesh screen formed with undulatingmesh material having a series of ridges spaced apart by a series ofvalleys, an optional perforated plate with an undulating shapecorresponding to the undulating mesh material of the at least one wiremesh screen, the at least one wire mesh screen on the corrugatedperforated plate, and a lower layer of wire mesh material, the lowerlayer of wire mesh material having a mesh size coarser than that of anylayer of the at least one wire mesh screen.

The present invention, in certain embodiments, discloses a screen for avibratory shaker for screening material flowing thereto, the screenhaving a frame with a plurality of spaced-apart frame openings, and aplurality of screen modules (or in other aspects, plugs) each disposedin a frame opening, each screen module having a module body with amodule opening and screen means (e.g. mesh, screen, openingstherethrough, etc.) at the module opening for screening material flowingthereto; such a screen wherein at least one or all screen modules isremovably disposed in its respective frame opening; such a screenwherein the frame has exterior sides defining a frame space within theframe and wherein the plurality of frame openings extend substantiallyall across the frame space; such a screen wherein the frame issubstantially flat or is corrugated; such a screen wherein the screeningmeans is screening material (e.g. any mesh, screen or combinationthereof) disposed over or in or over and in the module opening; such ascreen wherein the frame has holding means and the screen modules havereleasable attachment means (e.g. but not limited to a recess on onemember and a bead on the other) that cooperate with the holding means toreleasably mount the screen modules in the frame; such a screen whereinthe frame is substantially flat with a top surface and at least onescreen module (or all the modules) has a screening portion that projectsabove the top surface of the frame; such a screen wherein the frame hasa bottom and at least one screen module (or all of them) has a screeningportion that projects below the bottom surface; such a screen whereinthere are projecting plug portions or module portions both above andbelow a frame, plate or panel and, in one aspect, holes or openingsthrough the frame, plate or panel; such a screen wherein the pluralityof screen modules includes a first set of screen modules and a secondset of screen modules, the first set of screen modules having screeningmeans having a first mesh (or screen) of a first mesh (or screen) size,and the second set of screen modules having screening means having asecond mesh (or screen) of a second mesh (or screen) size, the firstmesh size different from the second mesh size; such a screen wherein thefirst set of screen modules are for dewatering the material flowing tothe vibratory shaker and the second set of screen modules are forclassifying the material; such a screen wherein the screening means isremovably secured to the screen modules; such a screen wherein thescreening means comprises a series of openings extending through themodule bodies; such a screen wherein each module body has a threaded endextendable through its respective frame opening and the screen includesa threaded nut for each screen module for mating with the threaded endof the module body to secure the screen modules in their frame openings;such a screen wherein the frame has a frame top surface and each screenmodule has a top surface which does not project above the frame topsurface; such a screen wherein the frame (plate, panel, etc.) iscorrugated including periodic raised portions and a plurality of supportstrips underlie and are attached to the frame, each support strip havinga support body having spaced-apart ends spaced-apart sides, and a topsurface, and at least one upturned finger projecting above the topsurface of the support body, the at least one upturned finger configuredand sized for contacting and supporting at least a part of a raisedportion of the frame; such a screen wherein the at least one upturnedfinger is a plurality of spaced-apart upturned fingers; such a screenwherein the at least one upturned finger has a curved top with a shapecorresponding to a shape of a raised portion of the frame; such a screenwherein the at least one upturned finger extends up from cuts (e.g. cutsin a plastic or metal strip disposed so that upon bending the finger(s)is created) in the support body and the at least one upturned finger isintegral with the support body.

The present invention discloses, in certain embodiments a screen for avibratory shaker for screening material flowing thereto, the screenhaving a frame with a plurality of spaced-apart frame openings, aplurality of screen modules (or in other aspects, plugs) each disposedin a frame opening, each screen module having a module body with amodule opening and screen means at the module opening for screeningmaterial (e.g. fluid, slurries, drilling mud, etc.) flowing thereto,wherein all the screen modules are removably disposed in theirrespective frame openings, wherein the frame has exterior sides defininga frame space within the frame and cross members which with the exteriorsides define the frame openings and wherein the plurality of frameopenings extend substantially all across the frame space, wherein theframe has holding means and the screen modules have releasableattachment means that cooperate with the holding means to releasablymount the screen modules in the frame, and wherein the plurality ofscreen modules includes a first set of screen modules and a second setof screen modules, the first set of screen modules having screeningmeans having a first mesh of a first mesh size, or the module bodyhaving openings therethrough of a first size, or both, and the secondset of screen modules having screening means having a second mesh of asecond mesh size, or the module bodies having openings of a second size,or both, the first mesh size (or first opening size) different from thesecond mesh size (or second opening size);

The present invention discloses, in certain embodiments, a frame for ascreen for a vibratory shaker, the frame having a body with sides andcross members defining a plurality of openings (or a plate or panel withsuch openings) for mounting therein in each opening a screen module,mounting means for securing the screen modules in the openings; and sucha frame wherein the mounting means include release means for releasablymounting each screen module in its respective opening.

The present invention discloses, in certain embodiments, a support stripfor supporting part of a screen used in a vibratory shaker, the supportstrip having a support body having spaced-apart ends spaced-apart sides,and a top surface, and at least one upturned finger projecting above thetop surface of the support body, the at least one upturned fingerconfigured and sized for contacting and supporting at least a part of araised portion of the frame; such a support strip wherein the at leastone upturned finger is a plurality of spaced-apart upturned fingers;such a support strip wherein the at least one upturned finger has acurved top with a shape corresponding to a shape of a raised portion ofthe frame; and such a support strip wherein the at least one upturnedfinger extends up from cuts in the support body and the at least oneupturned finger is integral with the support body.

The present invention, in certain embodiments, discloses a plug (ormodule) for disposition in an opening of a plug (or module) positioningmember of a screen assembly for a vibratory separator that receivesfluid with material therein for separation therefrom, the plug (ormodule) having a body, an opening through the body through which fluidis flowable, and screening apparatus at the opening for screening thefluid with material therein; such a plug or module wherein the screeningapparatus is a series of holes through the body; such a plug or modulewherein the screening apparatus is at least one, two, three or morelayers of mesh and/or screen material used with or without a series ofholes through the body, the layers of the same or different mesh oropening size; such a plug or module with holding apparatus on the bodyfor securing the plug to the screen assembly; such a plug or module withreleasable holding apparatus for releasably securing the plug to thescreen assembly; such a plug or module with a top surface and sized andconfigured so that the top surface will not project above a top surfaceof the screen assembly, frame, plate, or panel; such a plug or modulewherein the screening apparatus is releasably secured to the body; sucha plug or module wherein the plug or module has a length and a width andthe screen assembly has a length and a width and the opening in the plugor module positioning member (e.g. frame, plate, panel) has a length,and wherein the length of the plug is substantially equal to the lengthof the opening and the opening extends for substantially the length ofthe plug or module positioning member; such a plug or module wherein theplug or module positioning member is selected from the group consistingof a frame, a plate, and a panel and wherein the screening apparatusincludes screening material; and such a plug or module with a curved,convex, concave, slanted, or horizontal top on the body.

What follows are some of, but not all, the objects of this invention. Inaddition to the specific objects stated below for at least certainpreferred embodiments of the invention, other objects and purposes willbe readily apparent to one of skill in this art who has the benefit ofthis invention's teachings and disclosures. It is, therefore, an objectof at least certain preferred embodiments of the present invention toprovide:

New, useful, unique, efficient, nonobvious: screens and vibratorydevices with such screens;, plugs and modules for screens for vibratoryseparators, in one aspect releasably secured to the screen;three-dimensional screens formed with a flat plate, frame, or panel anda plurality of plugs or modules that project beyond the frame, etc.either above, below, or both; screen or frame, panel, or plate, supportstrips that have one or more upturned fingers formed by cutting thestrip member and bending the finger therefrom; and screens with at leastdual screening areas, e.g. an area for dewatering and an area forclassifying and/or an area for high wear and replaceable modules orplugs with appropriate screening and/or mesh material to effect this;screens that are easily repairable or have areas that are easilyreplaced; and such screens that are flat or corrugated.

The present invention, in certain embodiments, discloses a method formaking a plate mesh combination, the method including securing (e.g.,but not limited to, with adhesive and/or heat) at least one, two, threeor more meshes and/or screens to a plate, heating the plate, andcorrugating the plate with the mesh and/or screen thereon while itremains heated.

Certain embodiments of this invention are not limited to any particularindividual feature disclosed here, but include combinations of themdistinguished from the prior art in their structures and functions.There are, of course, additional aspects of the invention describedbelow and which may be included in the subject matter of the claims tothis invention. Those skilled in the art who have the benefit of thisinvention, its teachings, and suggestions will appreciate that theconceptions of this disclosure may be used as a creative basis fordesigning other structures, methods and systems for carrying out andpracticing the present invention. The claims of this invention are to beread to include any legally equivalent devices or methods.

The present invention recognizes and addresses the previously-mentionedproblems and long-felt needs and provides a solution to those problemsand a satisfactory meeting of those needs. To one skilled in this artwho has the benefits of this invention's realizations, teachings,disclosures, and suggestions, other purposes and advantages will beappreciated from the following description of preferred embodiments,given for the purpose of disclosure, when taken in conjunction with theaccompanying drawings. The detail in these descriptions is not intendedto thwart this patent's object to claim this invention no matter howothers may later disguise it by variations in form or additions offurther improvements.

BRIEF DESCRIPTION OF THE DRAWINGS

A more particular description of embodiments of the invention brieflysummarized above may be had by references to the embodiments which areshown in the drawings which form a part of this specification. Thesedrawings illustrate certain preferred embodiments and are not to be usedto improperly limit the scope of the invention which may have otherequally effective or legally equivalent embodiments.

FIG. 1A is a top view of a screen plug according to the presentinvention. FIG. 1B is a side view of an embodiment of a plug as in FIG.1A. FIG. 1C is a side view of an embodiment of a plug as in FIG. 1A.

FIG. 2A is a top view of a screen plug according to the presentinvention. FIG. 2B is a cross-section view along line 2B—2B of FIG. 2A.FIGS. 2C, 2D are side views of an embodiment of a plug as in FIG. 2A.

FIG. 3A is a top view of a screen plug according to the presentinvention. FIG. 3B is a cross-section view along line 3B—3B of FIG. 3A.FIG. 3C is a side view of an embodiment of a plug as in FIG. 3A. FIG. 3Dis a side view of an embodiment of a plug as in FIG. 3A. FIG. 3E is aside view of an embodiment of a plug as in FIG. 3A. FIG. 3F is a sideview in cross-section of a fastener for the plug of FIG. 3E.

FIG. 4A is a top view of a screen according to the present invention.FIG. 4B is an end view of the screen of FIG. 4A.

FIG. 5A is a top view of a screen according to the present invention.FIG. 5B is an end view of the screen of FIG. 5A.

FIG. 6A is a perspective view of a strip support according to thepresent invention. FIGS. 6B, 6D are end views of the strip support ofFIG. 6A. FIG. 6C is a top view of the strip support of FIG. 6A.

FIGS. 7A, 7E are top views of a strip support according to the presentinvention. FIG. 7B is a perspective view of the strip support of FIG.7A. FIGS. 7C, 7D are end views of the strip support of FIG. 7B.

FIG. 8 is a top schematic view of a screen assembly according to thepresent invention.

FIG. 9 is a side cross-section view of a screen assembly according tothe present invention.

FIG. 10A is a side cross-section view of a screen assembly according tothe present invention. FIG. 10B is a side cross-section view of a screenassembly according to the present invention.

FIG. 11A is a side cross-section view of a screen assembly according tothe present invention. FIG. 11B is a top view of the screen assembly ofclaim 11A.

FIG. 12A is a side cross-section view of a screen assembly according tothe present invention. FIG. 12B is a top view of the screen assembly ofclaim 11A.

FIG. 13 is a side cross-section view of a plug according to the presentinvention.

FIG. 14 is a side cross-section view of a plug according to the presentinvention.

FIG. 15A is a bottom view of a plug according to the present invention.FIG. 15B is a side view of the plug of FIG. 15A.

FIG. 16A is a bottom view of a plug according to the present invention.FIG. 16B is a side view of the plug of FIG. 16A.

FIG. 17A is a top view of a screen assembly according to the presentinvention. FIG. 17B is an end view of the screen assembly of FIG. 17A.FIG. 17C is an end view of an elongated plug of the screen assembly ofFIG. 17A. FIGS. 17D and 17E are end views of alternative elongated plugembodiments.

FIGS. 18A-18D are top views of prior art perforated plates.

FIG. 19A is a perspective view of a strip system according to thepresent invention. FIG. 19B is a cross-section view along line 19B—19Bof FIG. 19A. FIG. 19C is a cross-section view along line 19C—19C of FIG.19B. FIG. 19D is a cross-section view of a system as in FIG. 19A.

FIG. 20A is a cross-section view of a screen support member according tothe present invention. FIG. 20B shows a side cross-section view of thesupport of FIG. 20A.

FIG. 21A is a cross-section view of a screen support member according tothe present invention. FIG. 21B shows a side cross-section view of thesupport of FIG. 21A.

FIG. 22A is a cross-section view of a screen support member according tothe present invention. FIG. 22B shows a side cross-section view of thesupport of FIG. 22A. FIG. 22C is a cross-section view of a screensupport member according to the present invention.

FIG. 23A is a top view of a screen according to the present invention.FIG. 23B is a view along line 23B—23B of FIG. 23A. FIG. 23C is a viewalong line 23C—23C of FIG. 23B. FIG. 23D is a cross-section view of ascreen according to the present invention.

FIG. 24A is a perspective view of a screen according to the presentinvention. FIG. 24B is a bottom view, FIG. 24C a top view, FIG. 24D aside view, FIG. 24E a side view, and FIG. 24F an end view of the screenof FIG. 24A.

FIGS. 25A-25E are cross-section views of screen ramp portions accordingto the present invention.

FIGS. 26-28 are top views of screens according to the present invention.

FIGS. 29A and 29B are cross-section views of screen ramp portionsaccording to the present invention.

FIGS. 30A and 30B are cross-section views of screen ramp portionsaccording to the present invention.

FIG. 31 is a side view of a screen according to the present invention.

FIG. 32A is a top view of a screen according to the present invention.FIG. 32B is a cross-section view along line 32B—32B of FIG. 32A.

FIG. 33 is a perspective view of a system according to the presentinvention.

FIG. 34A is a top view, partially cut away, of a screen according to thepresent invention. FIG. 34B is an end exploded view of the screen ofFIG. 34A. FIG. 34C is an end view of the screen of FIG. 34A. FIG. 34E isa side exploded view of the screen of FIG. 34A. FIG. 34D is a side viewof the screen of FIG. 34A and an adapter for mounting the screen on avibratory separator apparatus. FIG. 34F is an end view of a screen,shown partially, on a mounting structure of a vibratory shakerapparatus. FIG. 34G is a side view of screen locking apparatus. FIG. 34His an end view of a bottom bar of the apparatus of FIG. 34G.

FIG. 35A is a top view, partially cut away, of a screen according to thepresent invention. FIG. 35B is an end exploded view of the screen ofFIG. 35A. FIG. 35C is an end view of the screen of FIG. 35A. FIG. 35D isa side exploded view of the screen of FIG. 35A.

FIG. 36A is a top view, partially cut away, of a screen according to thepresent invention. FIG. 36B is an end exploded view of the screen ofFIG. 36A. FIG. 36C is an end view of the screen of FIG. 36A. FIG. 36D isa side exploded view of the screen of FIG. 36A.

FIG. 37A is a side view of a screen locking apparatus according to thepresent invention. FIG. 37B shows the apparatus of FIG. 37A in anunlocked position. FIG. 37C is a top view of the apparatus of FIG. 37B.FIG. 37D is a side view of a screen locking apparatus according to thepresent invention.

FIG. 38A is a top view, partially cut away, of a screen according to thepresent invention. FIG. 38B is an end exploded view of the screen ofFIG. 38A. FIG. 38C is an end view of the screen of FIG. 38A. FIG. 38D isa side exploded view of the screen of FIG. 38A.

FIG. 39A is a top view, partially cut away, of a screen according to thepresent invention. FIG. 39B is an end exploded view of the screen ofFIG. 39A. FIG. 39C is an end view of the screen of FIG. 39A.

FIG. 40A is a schematic view of a prior art system. FIG. 40B is aschematic view of a system according to the present invention.

FIG. 41A is a top view partially cut-away of a screen according to thepresent invention. FIG. 41B is an exploded view of the screen of FIG.41C. FIG. 41C is an end view of the screen of FIG. 41A. FIG. 41D is anenlargement of part of the screen of FIG. 41C.

FIG. 42 is an end view in cross section of an alternative embodiment ofthe screen of FIG. 41A.

FIG. 43 is an end view of a screen according to the present invention.

FIG. 44A is a top view of a screen according to the present invention.FIG. 44B is an exploded view and FIG. 44C is an end view of the screenof FIG. 44A. FIG. 44D is an enlargement of a portion of the screen shownin FIG. 44C. FIG. 44E is an end view that shows an alternative structurefor the screen of FIG. 44A.

DESCRIPTION OF EMBODIMENTS PREFERRED AT THE TIME OF FILING FOR THISPATENT

As shown in FIG. 1A, a plug 160 according to the present invention has abody 161 and a mesh 162 formed integrally thereof. It is within thescope of this invention for the mesh to be a wire mesh or meshes (orscreens) secured to the body 161 or wire mesh over the integral mesh162. In certain aspects the plug 160 is a single piece member made ofplastic or urethane.

In the embodiment of FIG. 1B, the plug 160 has an upper member 163spaced apart from a lower member 164 by a snap recess 165 which is sizedto correspond to an edge of a screen opening so that the plug 160 may besnapped into and then held in the screen opening.

In the embodiment of the plug 160 in FIG. 1C, an upper member 166 isdisposed above a lower member 167. The lower member 167 is sized to fitin an opening of a screen. The plug 160 may be held in place in a screenopening by a friction fit and/or with a suitable glue, adhesive, orepoxy. Velcro™ material at plug edges and on opening edges may be usedto releasably secure any plug herein at or in an opening. Plugs ofdifferent screening material or mesh or mesh size may be used indifferent screen areas; e.g., but not limited to plugs with a 40 mesh atback edge of a screen and plugs with a 100 mesh at a front end of thescreen.

As shown in FIGS. 2A, 2B and 2C, a plug 170 according to the presentinvention has a body 171 and a mesh 172 formed integrally thereof. It iswithin the scope of this invention for the mesh to be any known mesh orscreen, meshes or screens, or combination thereof, including but notlimited to a layer or layers of plastic or synthetic mesh or a piece orpieces of perforated plastic or synthetics (bonded together, unbonded,or bonded at intermittent points) or a wire mesh secured to the body171. In certain aspects the plug 170 is a single piece member made ofplastic or urethane.

In the embodiment of FIG. 2A, the plug 170 has an upper member 173spaced apart from a lower member 174 by a snap recess 175 which is sizedto correspond to an edge of a screen opening so that the plug 170 may besnapped into and then held in the screen opening.

In the embodiment of the plug 170 in FIG. 2D, an upper member 176 isdisposed above a lower member 177. The lower member 177 is sized to fitin an opening of a screen. The plug 170 may be held in place in a screenopening by a friction fit and/or with a suitable glue, adhesive, orepoxy.

As shown in FIGS. 3A, 3B and 3C, a plug 180 according to the presentinvention has a body 181 and a mesh 182 formed integrally thereof. It iswithin the scope of this invention for the mesh to be a wire meshsecured to the body 181. In certain aspects the plug 180 is a singlepiece member made of plastic or urethane.

In the embodiment of FIG. 3A, the plug 180 has an upper member 183spaced apart from a lower member 184 by a snap recess 185 which is sizedto correspond to an edge of a screen opening so that the plug 180 may besnapped into and then held in the screen opening.

In the embodiment of the plug 180 in FIG. 3D, an upper member 186 isdisposed above a lower member 187. The lower member 187 is sized to fitin an opening of a screen. The plug 180 may be held in place in a screenopening by a friction fit and/or with a suitable glue, adhesive, orepoxy.

FIG. 3E shows an embodiment of the plug 180 with an upper body 188 and alower body 189 with threads 190 thereon. A fastener 191 (FIG. 3F) withinternal threads 192 threadedly mates with the lower body 189 toremovably attach the plug 180 in a screen opening. Internal threads maybe used on the plug 180 with an externally threaded fastener.

FIG. 4A shows a screen 330 according to the present invention with aplurality of ridges with ridge tops 332 connected to ridge sides 333with bottom member 334 between adjacent ridge sides 333. The ridge tops332 have a plurality of openings 335 each with a plug 336 thereinaccording to the present invention. The ridge sides 333 have a pluralityof openings 337 each with a plug 338 therein according to the presentinvention. The bottom member 334 has one or a plurality of at least twoor more openings each with a plug 339 therein according to the presentinvention. A plate 340 has the ridge tops 332, ridge sides 333 andbottom members 334, each with their respective openings. It is withinthe scope of this invention for some or substantially all (e.g. thetotal minus one, two, three, four, five, or up to twenty) of theopenings in the plate 340 to be covered with screen, screens, mesh ormeshes in any combination applied and secured in any known manner or inany manner disclosed herein. It is within the scope of this inventionfor any opening in the plate 340 to have a plug permanently or removablydisposed therein or for such a plug to be emplaced in any opening torepair damaged screen or to replace a previously used plug. Any plugdisclosed herein may be used with the screen 330. The plugs 342 are likethe plugs of FIGS. 1C, 2D, 3D or 3E. It is within the scope of thisinvention for the screen 330 to have any number of desired ridges 332 ofany suitable dimensions with corresponding ridge sides 333 and bottommembers 334, or with interconnected ridges having no bottom membertherebetween. Alternatively, pointed corrugations may be used with noflat top and no flat bottom or with a flat bottom and pointed top. Sucha screen (and any screen or screen assembly disclosed herein) may beused on a frame; on a flat perforated plate; on one or more bracesand/or strip supports (flat and/or corrugated; and corrugated tocorrespond to the shape of the screen 330's shapes); on a combinationthereof; and/or with upturned side edges or other connection apparatusfor connection to a vibratory separator or shale shaker.

It is within the scope of this invention for the plugs of FIGS. 2A-2Dand 3A-3E (and any plug disclosed herein) to be circular, oval, orsquare, rectangular, triangular, regular polygonal, polygonal elliptical(as viewed from above) or to be elongated as disclosed below. It iswithin the scope of this invention for mesh or meshes on or formedintegrally of any plug herein (described above or below) to be orientedand emplaced on a screen either parallel to or normal to the directionof flow of material onto the screen for dewatering or classifying asdesired. It is within the scope of this invention to provide a plug(described above or below) with both mesh or meshes formed integrallythereof and mesh or meshes applied thereunder or thereover. Upper plugparts may be made of plastic (or urethane) with lower parts made ofmetal, or vice versa. The plug body may be plastic or metal with plasticand/or wire mesh bonded to it. Different plugs may be used in the samescreen. Plugs can be any desired size. In one aspect plugs range from asmallest width of about 0.5 inches to one foot wide, or more and from alength of 0.5 inches to several feet. In one aspect plugs with differentmesh or screen than other plugs are used in the same screen to provide adifferent classification function in one screen. In one aspect plugs ofuniform size with similar or dissimilar mesh or screen are used.

FIG. 5A shows a screen 350 according to the present invention with aplurality of openings 351 and 352 in a plate 360. Plugs 353 are securedin some of the openings 351 and a plug 354 is in one of the openings352. Mesh (shown partially in FIG. 5A) covers substantially all of thetops of the plugs 353 and 354. Screen 355 covers openings that are notplugged. Screen 355 may be any known screen, screens, mesh, or meshesapplied to the plate 360 in any known manner or any manner disclosedherein. The plate 360 may be any known plate, flat or corrugated.

FIG. 6A shows a support strip 370 according to the present inventionwith a body 371, ends 372 and upturned fingers 373, 374. In one aspectthe strip 370 is metal (e.g. but not limited to carbon steel orstainless steel), and the fingers are upturned following a cut 375 inthe body 371 and then a cut to separate the fingers. These cuts are madeand sized, in one aspect, so that the fingers are sized and positionedto correspond to raised portions of a corrugated screen or of acorrugated plate. The strip 370 can be used as any strip disclosedherein or in pending co-owned application U.S. Ser. No. 08/786,515 filedon Jan. 21, 1997 entitled “Screen For Shale Shaker” incorporated fullyherein for all purposes. Alternatively, the strip 370 can be a moldeditem made as shown in FIGS. 6A-6C. It is within the scope of thisinvention to have a strip with three, four, five or more sets ofupturned fingers and, in one aspect, to have a set of fingers for eachraised portion of a plate and/or screen used with the strip. It iswithin the scope of this invention to use any desired number of stripswith a plate and/or screen. One or more sets of fingers 373, 374 may beused on a strip with one or more fingers 385 of the strip of FIG. 7A.FIG. 6D shows an alternative embodiment of the strip 370 with aninternal support 377 between fingers 373, 374. Such supports 377 may beglued in place to the interior surfaces of the fingers 373, 374. If thestrip 370 is metal and the supports 377 are metal, they may be glued,sintered, or welded in place. The supports 377 (and strip 370) may bemade of materials as described below for the supports and strips inFIGS. 19A-23D.

FIGS. 7A-7C disclose a support strip 380 for a screen and/or plate whichhas a body 381 (in one aspect made of metal) with ends 382 and a cut 383which has fingers 385. As shown in FIGS. 7B and 7C, the fingers 385 areupturned and have a top curved portion 384. In one aspect the top curvedportion 384 corresponds in shape to a curved portion of a corrugatedplate and/or screen used with one or more of the strips 380.Alternatively the strip 380 can be made of one integral plastic piece.Any desired number of fingers 385 may be provided. FIGS. 7D and 7E showan alternative embodiment of the strip 380 with an internal support 387beneath each finger 385. The supports 387 have an end portion 388extending over a top of the strip 380. The supports 387 may be securedto the interior surface of the fingers 385 and/or secured to or fastenedto the strip 380. The supports 387 as shown do not extend downward tothe lowest extent of the bottom of the strip 380, although this would bewithin the scope of the invention. The supports 377, 387 may be one or aseries of fluid flow holes therethrough—as may any support in FIGS.19A-23D. Any support disclosed herein may be fastened to a strip and/orscreen and/or plate with one or more fasteners and/or with Velcro™material.

The present invention discloses a method for making a screen assembly inwhich a perforated plate is sandblasted and/or washed with any suitabledegreaser and/or soap. Any suitable perforated plate may be used. In oneparticular embodiment the perforated plate has round holes about ¼ inchin diameter or square holes with a diagonal measurement of about ¼ inchwhich have centers that are about 0.030 inches apart and that areseparated from each other by about 0.050 inches of plate. Alternativelyholes with a ⅜ inch, or ½ inch diameter may be used. The plate, incertain aspects, is made of carbon steel, stainless steel, or plastic.The holes, in one aspect, are at a 45° angle to the direction of fluidflow across the plate. If desired, the plate can be sandblasted orsanded.

The plate is heated to about 450° F. (in an oven or heat press) and isthen dipped, preferably while positioned horizontally, into a fluidizedbed of epoxy, (or other suitable adhesive) to coat the plate with meltedepoxy powder in the bed. Heat in the plate permits the epoxy powder tobond to it in a semi-cured state. In another aspect powdered nylon, (orpowdered polyester, or any suitable powderized coating) is coated ontothe plate using a fluidized bed. In one aspect the epoxy is about 15 to30 mils thick and in another aspect is about 20 mils thick on top of theplate and about 5 mils thick on the sides and bottom.

One, two, three, four or more layers of wire mesh are then cut to coverthe pattern of perforations on the screen plate (in one aspect wider andlonger than the coated screen plate), in one aspect mesh of 2 mesh to500 mesh. The wire mesh and screen plate are placed on top of anon-stick panel (e.g. a panel made of 20 gauge steel with a Teflon(™)coating is applied to the panel; alternatively a 20 gauge steel sheetwith a 20 mil thick sheet of Teflon (™) material on it may be used). Thenow non-stick panel acts as a tray for sliding the plate/meshcombination into an oven and the panel prevents the screen plate coatingfrom sticking to the oven. Due to the Teflon(™) coating the platesurface adjacent to the wire mesh, the screen plate and wire mesh do notbond to the panel. The screen plate, alternatively, may be placed on topof the mesh or meshes. A second non-stick panel is then placed over thefirst plate/mesh/panel combination. This second panel non-stickingsurface is adjacent to the plate. In one aspect this second panel has asheet of self-adhesive Teflon(™) material on its lower side facing themesh on the plate. Instead of Teflon(™) material, any material may beused which will prevent the epoxy (nylon, polyester, etc.) from stickingto the panels. The two panels may be fastened together to providepressure to facilitate encapsulation of the mesh by molten epoxy.

The sandwich of panels, plate, and mesh is placed in an oven, e.g. for 6to 8 minutes at 340° F. to cure the epoxy. The cured screen plate isremoved from the oven and the mesh and epoxy are cut flush with thesides of the screen plate. It is known in the art to thus prepare aplate/mesh combination. However, the inventors are unaware of any priorart teaching: the re-introduction of the plate/mesh back into an oven;the re-heating of the plate/mesh; or corrugating a re-heated combinationof plate/mesh.

The plate with the mesh may then be corrugated or, alternatively, it isfirst placed back in the oven for about 2 minutes at about 450° F. Whilestill hot, the plate is removed from the oven and corrugated (e.g. usinga press brake). In one aspect a plate about 36 inches wide and about 47inches long after corrugations has corrugations with ridges that areabout an inch high. In one preferred embodiment the plate with the meshand cured epoxy is at a temperature of at least about 250° F. until thecorrugating operation is finished. With more flexible cured materials,e.g. nylon, it is not critical to maintain the relatively hightemperature level of the plate during the corrugation operation.Alternatively, the plate is not corrugated.

The resulting screen assembly may be attached to a frame or it may beprovided with upturned opposed edges for connection to a separator orshaker. In one aspect Velcro(™) material on the screen assembly is usedwith mating Velcro(™) material on a frame or on a separator or shaker toreleasably attach the screen assembly thereto. In another aspect thescreen assembly is thus connected to one or more support strips (e.g.but not limited to, any support strip described herein).

In one aspect such a screen assembly is placed on a frame coated withepoxy and the two items are held together between Teflon(™) materialsheets. This combination is then cooked at about 450° F. for about 8 to15 minutes to cure the epoxy and secure the screen assembly to theframe.

In one aspect a corrugated screen assembly as described above has thespaces below ridges capped or plugged at each end of the screenassembly.

FIG. 8 shows schematically a screen 450 with a plurality of screeningplugs or modules 451, 452, 453 that are removably secured incorresponding openings 454 in a plate 456. Each module may be any size.With modules larger than those shown (e.g. up to a largest dimension of6, 8, 12 or more inches or several feet; and in one aspect a screen withrelatively few modules e.g. as in FIG. 8) there are fewer modules overthe plate surface and with smaller modules (e.g. down to a largestdimension of about ½ inch) there are more modules over the platesurface. In one aspect the modules 451 have a relatively coarse metalmesh, e.g. 150 mesh screen; the modules 452 have a coarser mesh, e.g. 80mesh; and the modules 453 have a fine mesh, e.g. 200 mesh, with the flowof fluid to be treated from the fine to the coarse modules (right toleft in FIG. 8). Alternatively this pattern can be reversed; all themodules may have a substantially similar mesh; or any and all modulesmay have a combination of meshes thereon, including screens in layers ofdifferent mesh and/or screens or meshes made of different material, e.g.but not limited to carbon steel, stainless steel, Teflon(™) material,plastic, and/or urethane.

It is within the scope of this invention to provide any plug or moduledisclosed herein initially with no holes, perforations, or openingstherethrough and then, e.g. later at a job site, to perforate the plugor module with the desired number and desired size openings, holes, orperforations or combination thereof. Such openings (and holes oropenings for any plug or module disclosed herein) may be normal to thedirection of the flow of fluid flowing above the hole, etc. (e.g. forclassification) or at an angle other than perpendicular to suchdirection of flow (e.g. for dewatering to remove a large, preferablymaximum, amount of liquid from a product).

With respect to the screen of FIG. 8 (or any other screen disclosedherein) it is within the scope of this invention for any plug or module,or any group thereof, to be fashioned for dewatering and/or forclassification. A single screen may, therefore, have an area primarilyfor dewatering a product flowing thereacross and an area for classifyingcomponent materials of the product. Plugs and modules disclosed hereinmay be made of metal, plastic, fiberglass, cermet, urethane, KYNAR,polymeric material, BUNA N, Teflon(™) material, or polyvinylidenefluoride. In one aspect a screen is provided with plugs or modules madeof urethane (or similar material) for a high wear area (e.g. at an areaof the initial introduction of a slurry to a first screen, the areawhich first encounters fluid and/or product to be treated); and a lowerwear area with plugs or modules with metal wire mesh.

Square plugs or similar plugs fitted with woven mesh (e.g. rectangularwoven mesh) can be fitted to provide a screen for classifying ordewatering. With rectangular openings, in one aspect flow parallel to along opening is used for dewatering and flow perpendicular to a longopening is used for classification.

FIG. 9 shows a screen assembly 460 with a plate 462 having holes 463therethrough. A plug 464, 465, or 466 is removably secured in each hole463. The plugs convert the plate into a 3-D corrugated screen assembly.It is within the scope of this invention for the plugs to have anydesired shape and size to make a screen assembly with ridges of anyshape and size—the ridges being part of the plugs. The plugs may bediscrete separate items with a plurality of them spaced apart or theymay be elongated members, e.g. two, four, twelve, twenty four, thirty,thirty six or more inches long and one, two, three, four or more incheswide.

The plug 464 has openings 467. Any number of openings of any desiredsize may be used. A mesh 468 covers the exposed surface of the plug 464.The plate 462 has optional openings 469 (any desired number and in anydesired pattern) which may be sized for dewatering, separation, orclassifying.

The plugs 465 have openings 469 and have no mesh thereon. The plug 466has two mesh layers 470 and 471 and holes 472. Any combination of anymesh made of any material may be used on the plugs 464, 465, 466.Grooves 475 permit the plugs to be snapped into the holes 463.Alternatively the plugs can be permanently or semi-permanently bonded tothe plate. Failed or damaged plugs may be replaced with little or noloss of screening area.

FIG. 10A shows a screen assembly 480 according to the present inventionwith a plate 482 having holes 481 therethrough and thereacross. A groove484 permits plugs 485 to be snapped into the holes 481. A top perforatedplug body 483 projects above the plate surface and a bottom perforatedplug body 488 projects below the plate surface. Perforations 486 in thetop perforated plug body may be similar to or different fromperforations 487 in the bottom perforated plug body in size anddisposition and they may be angled differently. Top and bottom plugbodies may be made of similar or different material and they may haveone or more meshes (metal or otherwise thereon). As with the plugs ofFIG. 9 and others disclosed herein, the plugs 485 may be any desiredsize, length, width, and cross-sectional shape.

FIG. 10B shows a screen assembly 490 with plugs as in FIG. 9 above a topsurface of the plate 462 and bottom plug bodies like those of the plugs485 (FIG. 10A). Holders 491 hold the bottom plug bodies on the plate462. The holders 491 use the grooves 484 as is shown in FIG. 10A. Thesections of the plate 462 between plugs may have holes or openingstherethrough. The holes 463 in the plate 462 may be sized and configuredas any opening or hole disclosed herein, including but not limited to anarray of adjacent holes or openings (square, hexagonal, circular,triangular, rectangular) extending across the entire surface of theplate 462 or a series of relatively long openings extending from oneside of a square or rectangular plate 462 to the other so that acorrugated screen is formed with both upper and lower corrugatedsurfaces defined by the plugs, the plugs extending for substantially thewhole length of the relatively long openings.

FIGS. 11A and 11B show a screen assembly 630 according to the presentinvention with a plate 631 (shown partially) having a plurality ofopenings 632 thereacross. The openings 632 may initially be covered byone or more meshes and/or screens (as with all plates disclosed herein)or, alternatively all the openings 632 may have a plug 634 therein (aswith all plates disclosed herein). Also, a plug 634 may be used torepair damaged mesh/screen over an opening with little or no loss ofscreening area. The plug 634 has a tapered body 635 corresponding to atapered surface of the openings 632 and a lower lip 636 that permits theplug to be snapped into the openings 632 and held in the openings 632.The plug 634 has holes 637 extending therethrough. Alternatively theplugs 634 may be solid or may have more or less holes of larger orsmaller diameter than those shown. The plug 634 as shown in FIG. 11B iselliptical as viewed from above; however it is within the scope of thisinvention to use any suitable shape, including but not limited tosquare, circular, triangular, hexagonal, polygonal, regular polygonal orrectangular. Also, a mesh, meshes, screen, and/or screens may be appliedon the top surface of the plugs 634. It is critical for certainparticular embodiments of the screen assembly 630 that the top surfaceof the plugs 634 is substantially flush with the top surface of theplate 631 (or with mesh etc. on top of the plate). Materials disclosedherein may be used for the plugs and plate.

FIGS. 12A and 12B show a screen assembly 640 according to the presentinvention with a plate 641 (shown partially) having a plurality ofopenings 642 thereacross. The openings 642 may initially be covered byone or more meshes and/or screens (as with all plates disclosed herein)or, alternatively all the openings 642 may have a plug 644 therein (aswith all plates disclosed herein). Also, a plug 644 may be used torepair damaged mesh/screen over an opening. The plug 644 has a body 645and a groove 646 that permits the plug to be snapped into the openings642 and a bead 649 on the plate 641 to enter into the groove 646 to holdthe plugs 644. The plug 644 has holes 647 extending therethrough.Alternatively the plugs 644 may be solid or may have more or less holesof larger or smaller diameter than those shown. The plug 644 as shown inFIG. 12B is circular as viewed from above; however it is within thescope of this invention to use any suitable shape, including but notlimited to square, circular, elliptical, hexagonal, polygonal, regularpolygonal, triangular, or rectangular. Also, a mesh, meshes screen,and/or screens may be applied on the top surface of the plugs 644. It iscritical for certain particular embodiments of the screen assembly 640that the top surface of the plugs 644 is substantially flush with thetop surface of the plate 641 (or with mesh etc. on top of the plate).Materials disclosed herein may be used for the plugs and plate.

FIG. 13 shows a plug 650 according to the present invention with a body651 and a top convex surface 652. A series of holes 653 extend throughthe plug 650. The plug 650 may be any desired size or shape.

FIG. 14 shows a plug 660 according to the present invention with a body661, a top convex surface 662, and a mesh 668 thereon. A series of holes663 extend through the plug 660. The plug 660 may be any desired size orshape. The holes 653 (FIG. 13) and holes 663 (FIG. 14) may be anydiameter and there may be any desired number of them.

FIGS. 15A and 15B show a plug 670 according to the present inventionwith a body 671 and a series of holes 673 extend therethrough. The plug670 may be any desired size or shape. The plug 670 is made of flexiblematerial and has an expansion ring 675 therein that pushes the plugsides outwardly to facilitate maintenance of the plug 670 in position ina plate opening and/or put the plug's mesh or meshes in tension. A meshor screen 675 is on top of the plug 670.

FIGS. 16A and 16B show a plug 680 according to the present inventionwith a body 682. A series of holes 683 extend through the plug 680. Theplug 680 may be any desired size or shape. The plug 680 is made offlexible material and has expansion springs 684 and 686 that push theplug sides outwardly to facilitate maintenance of the plug 680 inposition in a plate opening and/or put the plug's mesh or meshes intension. One, two, three or more springs may be used. Meshes 681 and 688are secured on the plug 680.

FIGS. 17A and 17B show a screen assembly 500 according to the presentinvention with a perforated plate 502 having perforations 504 extendingtherethrough from top to bottom. Any number and size perforations may beemployed in any desirable pattern or positioning on the plate 502.Dovetail recesses 506 extend across the plate 502. Holes 505 extend fromthe recesses through the plate 502. A corresponding dovetail base of anelongated hollow plug 510 is held in each dovetail recess 506. Each plug510 has a series of perforations or holes 508 therethrough and one ormore bottom holes 509. Any number and size holes may be employed in anydesired pattern or positioning on the plugs 510. The plugs 510 may beheld tightly in the recesses 506 with a tight friction fit and/or withwelding or epoxy. In one aspect the plugs 510 are removably insertedinto the dovetail recesses 506 for easy replacement and/or repair. Anyhole in a plug 510 may be repaired with a plug as previously describedabove for repairing damaged or torn mesh or screen. The perforations 504and/or the holes 508 may be covered with any known mesh, meshes, screenor screens, bonded or unbonded, in any combination or layers.

FIG. 17C shows one of the plugs 510.

FIG. 17D shows an alternative embodiment of an elongated hollow plug 520according to the present invention that has a body 522, holes 524therethrough, a base 526 with holes 528 therethrough and a dovetailportion 529 through which the holes 528 also extend. To enhance sealingof the plug/plate interface, a seal bead 521 is provided along each sideof the plug along its entire length. Alternatively such a seal membermay be formed of or secured to the plate with which the plug 520 isused. The seal bead or member may be plastic, rubber, or any knownsuitable sealing material. Such a bead may also serve to stabilize theplug in place on the plate.

FIG. 17E shows an alternative elongated solid plug 530 with a body 532having a series of holes 534 therethrough and a dovetail base 536. Amesh or screen 538 is secured over the plug body 532 covering the plugon its top surface. Fluid to be treated flows through the screen 538 andthrough the holes 534. Two or more meshes and/or screens may be used.

FIGS. 18A-18D show known perforation patterns for plates used withscreens which may be used with plates and/or screen assemblies accordingto the present invention. The direction of fluid flow on the plates ofFIGS. 18A-18D may be from top to bottom (as viewed in the Figures) orside to side (as viewed in the Figures).

Pending U.S. applications Ser. Nos. 08/598,566 and 08/786,515,identified above, are incorporated herein in their entirety for allpurposes and copies of which are attached hereto as an Appendix.

FIG. 19A shows a screen frame 700 according to the present invention. Inone aspect the frame 700 is made from a single sheet or frame piece fromwhich areas 702 are removed, e.g. but not limited to by an appropriatesaw or laser, to form outer sides 703, 704, 705, 706 and cross strips707 and cross strips 708. Each cross strip 708 has two raised portionsor humps 709. It is within the scope of this invention for any of thestrips 707, 708 to have one, two, three, four five or more humps 709.

As shown each hump 709 has an internal support 710 therebeneath. Thesupports 710 are secured to a strip's underside by any suitable means,including, but not limited to, glue, adhesives, epoxy, sintering, andwelding. The strips 707, 708 and the supports 710 may be made of anysuitable metal, plastic, fiberglass, or composite material.

As shown in FIGS. 19B and 19C the inner surface of a top of the raisedportion or hump 709 is spaced apart from a top surface of the supports710 to facilitate fluid flow over and around the supports 710.

As discussed below, the strips 707, 708 and/or supports 710 may have aseries of fluid flow holes therethrough. As shown in FIG. 19D a hump 711(like the humps 709, FIG. 19B) has a series of fluid flow holes 712therethrough and a support 713 (like the supports 710, FIG. 19B) has aseries of fluid flow holes 714 therethrough.

FIGS. 20A and 20B shows a hump 715 (like the humps 709, 711) on a strip716. The strip 716 has a series of fluid flow holes 719 therethrough,including holes through the hump 715. An internal support 717 with aseries of fluid flow holes 718 therethrough is substantially as wide asthe strip 716.

FIG. 21A shows a hump 720 (like the humps in FIGS. 19B, 19D, 20A) of astrip 721 (like the strips 708, 716) has an internal support 722; butthe support 722 viewed in cross-section as in FIG. 21A, occupiessubstantially all of the space under the hump 720 when viewed this way.The support 722 and/or hump 720 may have a series of fluid flow holestherethrough. The support 722, as is true of the supports in FIGS. 19D,20A, 22A, 22C, 23B, and 23D, may be secured to a strip's underside as isa support 710 (FIG. 19B) and the strips in these figures and thesupports may be made of any of the materials listed above regarding thestrips 707, 708 and supports 710.

FIGS. 22A and 22B show a hump 725 of a strip 726 with an internalsupport 727 adhesively secured to the strip 726 with epoxy.Alternatively, the support 727 may be welded to the strip 726.Preferably when viewed as in FIG. 22B the support 727 occupies less than10% of the area beneath the hump 725 and most preferably less than 5%.As with any other internal support and hump disclosed herein, the hump725 and/or support 727 may have one or a series of fluid flow holestherethrough, as shown with the holes 728, 729 in FIG. 22C.

FIGS. 23A-23C illustrate changes to a screen assembly 730 disclosed inU.S. Pat. No. 5,720,881 which is incorporated fully herein. The screenassembly 730 has a plate 731 with holes 738 therethrough and amulti-layer screen 732 epoxied together and bonded to the plate 731.

As shown in FIG. 23B, support 733 underlies a ridge 734 of the screen732 and support 735 with a series of fluid flow holes 736 therethroughunderlies a ridge 737.

It is within the scope of this invention to use one or more supports 733and/or 735 (and/or one or more of any of the supports disclosed herein)under one, two, three, more than three, or all of the ridges of thescreen 732 (or of any screen or screen assembly disclosed in U.S. Pat.No. 5,720,881). In one aspect each ridge may have a series of spacedapart supports and, in another aspect, supports under one ridge areoffset from those under another ridge.

Although it is not preferred, in certain embodiments the support(s) maybe loose under the ridges. As shown in FIG. 23B the support 733 issecured to the screen 732 and to the plate 731 and the support 735 issecured to the screen 732.

As shown in FIG. 23C the width of a support may be such that, as viewedfrom above, it does not block off the openings 738 (support 733) or,alternatively it does block off openings 738 (support 736).

FIG. 23D shows a screen 740 like the screen assembly 730's screen 732,but with no lower plate 731. It is to be understood that the screens 732and 740 represent any known single or multi-layer screen or screenassembly with screen(s) bonded together or unbonded. It is within thescope of this invention to use one or more supports (any disclosedherein) with each of the various screen assemblies disclosed in U.S.Pat. No. 5,720,881 including but not limited to those of this patent'sFIGS. 2, 4, 8 and 9.

Ridges 741, 742, 743 of the screen 740 each has an internal support 744,745, 746, respectively secured thereto and thereunder. It is within thescope of this invention for the screen 740 to have only supports 744,745, or 746, to have them under each ridge, for such supports to extendalong and under the entire length of a ridge, or for there to be aplurality of spaced apart supports beneath each ridge. The support 746is shown with a series of fluid flow holes 747 therethrough, but it maybe solid and either or both of the supports 744, 745 may have a seriesof fluid flow holes therethrough.

FIG. 24A shows a screen 800 according to the present invention with mesh802 supported on spaced-apart straps 806. The mesh 802 may be anysuitable known mesh, screen, meshes, screens, or combination thereof,secured together or lying on each other and/or partially bonded orsintered together, or so connected to each other over substantially allof their area. In the screen 800, the mesh 802 is, in one aspect, a wiremesh that is bonded to the straps 806.

The straps 806 are secured to hookstrips 804, e.g. as previouslydescribed for straps herein.

As shown, the screen 800 has three spaced-apart ramps 808, 810, 812. Adewatering area or pool 822 is defined between the two ramps 808, 810and a dewatering area or pool 820 is defined between the two ramps 810,812. Side flow paths 824, 826 are positioned between ends of the ramps808, 810, 812 and the hookstrips 804.

In one aspect the ramp 808 is located so that fluid material isintroduced onto the screen 800 in an area behind (to the left in FIG.24C) the ramp 808 and which includes one of the straps 806 therebeneathto counter effects of the impact of the fluid material on the wire mesh802 in this area. Also such a location of the ramp 808 with respect tothe strap 806 facilitates dewatering of solids in this area whileinhibiting screen wear. Liquid rising to the top can exit through thescreen ramp. Similarly a strap 806 traverses the areas 822 and 826.

Alternatively, the ramp portions and straps may be positioned so thatany or part of the ramp portions overlie a strap or a portion of astrap. The ramp portions may be spaced apart any desired distance. Inone aspect the screen 800 is about 36 inches by 45½ inches; theright-hand edge (as viewed in FIG. 24C) of the ramp 808 is between aboutthree to about five inches or more from the left-hand edge of the ramp810; the right-hand edge of the ramp 810 is between about three to aboutfive inches or more from the left-hand edge of the ramp 812; theright-hand edge of the ramp 812 is between about three to about fiveinches or more from the right edge of the screen 800; and the ramps arebetween about three to about five inches wide (horizontal dimension asviewed in FIG. 24E) and about ½ inch high (as in FIG. 24E). Each ramp808, 810, 812 has a ramped surface 808 a, 810 a, 812 a, respectively atan angle, preferably, between about twenty to about forty degrees fromthe horizontal, more preferably between about twenty-five to aboutthirty degrees, and in one particular aspect about twenty seven-degrees.Each ramp also has a rear face at between about eighty to about onehundred twenty-five degrees to the horizontal, more preferably betweenninety and one hundred twenty degrees, and in one particular aspectabout one hundred fifteen degrees.

FIGS. 25A-25E show cross-section views for a variety of ramp profiles840-848 according to the present invention. In certain preferredembodiments ramp heights range between ¼ inch and 1½ inches and rampwidths range between about one inch and about five inches.

It is within the scope of this invention to provide a screen with one,two, three, four, five, six or more ramps and the ramps may be the sameor different on a multi-ramp screen—and may be any ramp with any profiledisclosed herein. FIG. 26 shows a screen 850 like the screen 800 (andlike numerals indicate the same parts), but with an additional series oframps 808 a, 810 a, 812 a.

FIG. 27 shows a screen 860 like the screen 800 (and like numeralsindicate the same parts), but with only one ramp 812.

FIG. 28 shows a screen 870 like the screen 800 (and like numeralsindicate the same parts), but with divided ramps 811, 813, 815 (eachwith ramp portions 811 a, 811 b; 813 a, 813 b; 815 a, 815 b,respectively) each having a flow path 821, 823, 825 between rampportions. It is within the scope of this invention to provide: a fullundivided ramp for any of the ramps 811, 813 or 815; a flow path betweenramp portions of any desired width, including, but not limited to,between about three inches and about five inches; and to provideadditional flow paths (one, two, or more) through the ramp portionsthemselves. In one aspect, ramp portions are offset to provide a moretortuous path for wet solids. Any one or two of the paths 821, 823, 825may be deleted by providing an undivided ramp across the screen 870.

In any screen disclosed herein with one, two or three ramps on one sideof the screen (as viewed from above), e.g. as in FIGS. 24D, 27 and 28,it is within the scope of this invention to provide one, two or moreramps on the other side of the screen.

Different ramp profiles may be used on the same screen. FIG. 29A showspart of a screen 874 according to the present invention (like the screen800) with mesh 875 and spaced-apart ramps 877, 878. Straps 876 (like thestraps 806) are beneath the mesh 875. FIG. 29B shows a differentlocation for the straps 876.

FIG. 30A shows a screen 880 according to the present invention (like thescreen 800) with mesh 885 in straps 886 (like the straps 806) and ramps887, 888. FIG. 30B shows the screen 880 with additional straps 886. Thescreens of FIGS. 29A-30B may have hookstrips and straps like the screens800, 850, 860 and/or 870.

Although a series of spaced-apart parallel straps is not the legalequivalent of a perforated plate, a screen as described herein (FIGS.24D-30B) and/or any ramp or ramp portion as described herein may be usedon a perforated plate and, in particular aspects, on a perforated plateof any prior art screen instead of the prior art mesh(es) and/orscreen(s) used thereon, including, but not limited to, with flat and/orthree-dimensional screens and/or with the plates of the screens ofprevious U.S. Pat. Nos. 4,575,421; 5,720,881; 5,417,858; 5,783,077;5,417,859; 5,417,793; 5,636,749; 4,033,865; 5,221,008; 4,819,809;4,065,382; 3,929,642; and 5,211,291. Such a screen is illustrated by thescreen 890 of FIG. 31 which has mesh 892; ramps 893,.894, 895; and aperforated plate 896 (side view shown without showing perforations thatdo extend through the plate). It is also within the scope of thisinvention to use a perforated plate under a portion of the screen meshand one or more straps under the remaining portions of the screen mesh,with one or more ramped screen portions over the perforated plate and/orover the strap(s).

FIGS. 32A and 32B show a screen 900 like the screen 860 (like numeralsindicate the same parts) but with an additional ramp 812 c at the sideof the screen opposite the side with the ramp 812 d. Such a ramp 812 cmay be used with the screens 800 or 870. Flow paths may be used throughthe ramp 812 c and/or through the ramp 812 d. The ramps 812 c and 812 dare separate pieces that are bonded to, sintered to, and/or secured tothe mesh 802 and/or to a strap 806, e.g. by any structure or securementapparatus or method disclosed herein (e.g., but not limited to as inFIGS. 1A, 3D, 9-17E). Any ramp or ramp portion herein may also be soconnected to a mesh, screen, plate, and/or strap and/or secured to themesh (screen, strap, and/or plate), e.g. by any structure or securement.

Referring now to FIG. 33, a vibratory separator system 910 according tothe present invention has a screen 920 (with screen or screening clothor mesh as desired) according to the present invention mounted onvibratable screen mounting apparatus or “basket” 912. The screen 920 maybe any screen disclosed herein or have any combination of any feature orfeatures of any screen or screen part disclosed herein; and any suchscreen may be used with any appropriate shaker or screening apparatus.The basket 912 is mounted on springs 914 (only two shown; two as shownare on the opposite side) which are supported from a frame 916. Thebasket 912 is vibrated by a motor 922 and interconnected vibratingapparatus 918 which is mounted on the basket 912 for vibrating thebasket and the screens. Elevator apparatus 928 provides for raising andlowering of the basket end. The screen 920 may be any screen disclosedherein, including, but not limited, those of FIGS. 24D-32A. As shown thescreen 920 is like the screen 800 of FIG. 24D. In certain aspects usinga ramped screen as in FIG. 24A produces processed cuttings with an oilcontent of 3% or less and a water content of 20% or less when the screenis used in a multi-screen BRANDT LCM2D shaker beneath two standard DX210 screens; and in a particular embodiment of such a screen, the oilcontent is less than 2% with a water content less than 15%. Any rampdisclosed herein may have a curved or undulating shape as viewed fromabove instead of the straight shape, e.g. as disclosed in FIG. 26. Oneor more ramps and/or divided ramps as described above may be used on anyscreen disclosed herein having one or more screens formed with anundulating shape.

FIGS. 34A-34E shows a screen 930 according to the present invention withwire mesh layers 931, 932, 933 (any or any two of which are optional) ona perforated corrugated plate 934 which is mounted over rods 936.Optionally, the layer(s) may be adhered (adhesively, by sintering,and/or bonding) to the plate. The plate 934 is optional. [FIGS. 38A-38Dshow a screen 930 a without the plate 934 (like numerals indicate thesame parts).] The rods may be made of metal (e.g. steel, stainlesssteel, zinc, zinc alloys, aluminum, aluminum alloys, copper, copperalloys) plastic, composite or fiberglass. Top bars 935 extend along twosides of the screen 930. Open ends of the screen 930 on two sidesthereof are plugged with plugs 937 which are made of any suitable metal,plastic (e.g. urethane), wood, fiberglass, or composite material and areheld in place by a friction fit and/or suitable adhesive including butnot limited to epoxy or glue (e.g. but not limited to commerciallyavailable 3M Jet Melt or 3M TS230). Also, preferably, front and rearedges 942, 943 of the screen and the plate are encapsulated by theadhesive or glue (e.g. but not limited to urethane). A bottom bar 940has recesses 941 for receiving the rods 936 and a plurality of boltholes 948 for attaching the bottom bar 940 to a typical part or wear orseal strip of known shakers. Optionally, the rods may be adhered to therecesses. Alternatively, bolts through a shaker basket may extend intothe side of the bottom bar 940. Seal material (e.g. rubber, plasticBUNA-N, etc.) 944 may be used on top of the bottom bar 940.

In one aspect the wire mesh layers 931 and 932 are either 1, 2, or 3mesh and the layer 933 is of a coarser mesh, e.g. 12×12 down to 8×8 (orbetween 8×12 and 12×8). It is also within the scope of this inventionfor the layers 931, 932, 933 to be any mesh size. The plate 934 is, incertain aspects, made of metal, e.g. but not limited to 20 gauge carbonsteel. In one aspect a screen 930 is made by bonding the layers 931 and932 into a sheet with epoxy across substantially the entire surfaces ofthe layers; then the resulting sheet is corrugated and the layer 933 isbonded to the sheet.

FIG. 34F shows a screen 930 in place on a ledge 947 of a shaker basket946 below a locking bar 938. FIG. 34G shows free latch levers 939 one ina “down” locking position (the one to the right in FIG. 34G) locking ascreen 930 to the shaker basket and one in an “up” position from whichit is releasable to release the screen from the basket.

FIGS. 35A-35D show a screen 950 according to the present invention withwire mesh layers 951, 952, 953 (any or any two of which may be deleted),a perforated corrugated plate 954 (which is optional), and a layer ofwire mesh 959 which may be any desired mesh size but which is, incertain embodiments a coarser mesh than any of the meshes 951-953. Inone particular aspect the wire mesh layer 959 is between 1×1 and 4×4mesh (including between 1×4 and 4×1 mesh). In particular embodiments thelayer 959 is 12×12, 8×8 or 4×4 mesh, and may include meshes between 8×12to 12×8. The layers may have upturned ends 958 so that the screen 950may be used with any standard clamp/hookstrip arrangement. These layersmay be bonded together as a unit. The upturned ends may be formed beforeor after bonding. Preferably the front and rear edges of the screen 950are encapsulated by adhesive or glue as in the screen 930 and plugs 957plug screen ends as do the plugs 937. FIGS. 39A-39C show a screen 950 alike the screen 950, but without the plate 954 and with a wire meshlower layer 959 a like the layer 959 (like numerals indicate the sameparts). As with any screen herein, multiple wire meshes may be bondedand/or secured together prior to corrugating.

FIGS. 36A-36D show a screen 960 according to the present invention withwire mesh layers 961, 962, 963 (any or any two of which may be deleted),grid 969 of corrugated rods 966, a plurality of rods 965 underlyingparts of the rods 966, and encapsulation material 967 (like that of thescreen 930) which encapsulates front and rear edges of the wire meshesand rod grid. Alternatively, some of the internal bars may be includedin the encapsulation material. Top bars 965 are like the top bars 935 ofthe screen 930 and the screen 960 may be used with the locking apparatusshown in FIG. 34G. A bottom bar 968 is like the bar 938 with side boltholes 964 for bolting the bar 968 and a screen attached thereto to ashaker basket. The bar 968 has rod recesses 964 and a top seal layer 968a (like the material 944 of screen 930).

FIGS. 37A-37D illustrate another screen locking mechanism 970 forreleasably holding a screen to a basket of a vibratory separator. E.g.,a screen 930 with its adapter bar 940 is positioned on a basket ledge(not shown). As shown in FIG. 37A the mechanism 970 releasably holds thescreen 930 in place. As shown in FIG. 37B, the mechanism 970 is in an“unlock” or release position permitting the screen 930 to be removedfrom the shaker basket.

A body 971 has a bracket 972 bolted to a shaker basket wall with boltsthrough holes 973 or appropriately secured to another part of a shaker.The body 971 has a hole 974 through which movably extends a rod 975.Leaf spring 976 are secured to the body 971. The rod 975 is pivotablymounted to a bar 977 with a pin 978. A distal end of the bar 977 ispivotably mounted around a pin or pivot member 979 mounted to the leafsprings. Bolts 981 secured to the pivot member 979 movably extendthrough holes 982 in leaf springs 976 and nuts 983 prevent the boltsfrom escaping from the holes 982 in the leaf springs. The member 979fits through the bar 977. In both over and under center positions, thebar 977 is releasably locked in place. A “locked” position is shown inFIG. 37A. In a locked position, a lower end of the rod 975 bears againsta top bar of the screen 930 to releasably hold the screen 930 in ashaker basket.

FIG. 37D shows another releasable locking mechanism 986 for releasablyholding a screen to a shaker basket with a bar 987 and plunger 988 in anunlocked position, with a locked position indicated by the bar 987 andplunger 988 in dotted line. A body 989 includes a shaker basket mountingbracket 991 with bolt holes 992 and holes 993 through which movablyextends a rod 994 of the plunger 988. The rod 994 is pivotably securedto the bar 987 with a pin 995 and a distal end of the bar 987 ispivotably mounted about a pivot member 997. A spring 995 urges theplunger downwardly and is biased to help maintain the apparatus in areleasable locked position. A spring stop 999 is on the rod 994.

FIG. 41A shows a screen 1110 according to the present invention with alower base, support or frame 1112, three undulating mesh screens 1114 onand/or bonded to the frame 1112, and an upper mesh or screen 1116. Thescreens 1114 may themselves be bonded together, e.g. with epoxy,welding, and/or sintering. Rubber strips, plastic strips tape, cushionor cushions 1118 are positioned between the screen 1114 and the upperscreen 1116. The strip(s) or cushion(s) 1118 are optional. As shown thestrip(s), tape(s), or cushion(s) 1118 are secured to the screen 1114 (orto crests thereof), but it is within the scope of this invention tosecure them (or some of them) to the screen 1116. To effect suchsecurement any suitable glue, epoxy, weld, and/or sintering may beemployed. The frame 1112 may be any suitable known base, frame orsupport.

It is within the scope of this invention for the screen 1114 to be anyknown screen, mesh, screens, meshes, or combination thereof, bondedtogether, unbonded, or bonded at only certain locations and with anyknown shape as viewed either from above or on end (as in FIG. 41A). Itis within the scope of this invention for the upper screen 1116 to beany known screen, mesh, screens, meshes, or combination thereof, bondedtogether or unbonded, and with any known shape. As shown in FIG. 41B,the screen 1114 is three mesh screens bonded together with coarser meshon the bottom, medium mesh in the middle, and finer mesh on top. Thescreen 1116 as shown may be a scalping screen of a mesh coarser than thefinest mesh of the screen 1114 or of a multi-layer coarser mesh. Inanother aspect the screen 1114 is a single screen of closely woven meshmade of any suitable material, e.g. stainless steel and/or plasticmaterial and the screen 1116 is a single screen of coarser mesh made ofany suitable material (e.g. but not limited to stainless steel and/orplastic), with the screen 1114 on a metal or plastic frame or support.Alternatively or additionally, instead of the frame 1112 any knownperforated plate, strip, or series of straps or strips may be used. Aseries of strips is not legally equivalent to a perforated plate.

In one aspect the strips 1118 are fused plastic strips aligned withpeaks of the undulating fine mesh. Such strips may be made of rubber(e.g. nitrile) or plastic, e.g. polypropylene, to inhibit or preventabrasion of the finer meshes. Such strips can be glued to the bottom ofthe screen 1116 and/or the screen 1114. Also the screen 1116 can beglued to the screen 1114.

End plugs 1113 and 1115 (FIG. 41D) sealingly close off open ends of thescreen 1110. These end plugs may be made of rubber, metal, wood,plastic, Teflon™ material, or urethane. The plugs 1113 extend along twosides of the screen along crests of the screening material to completelyseal the sides. The plugs are held in place by friction fit, glue,epoxy, welding and/or sintering. Alternatively, the ends may be coveredwith screen material.

Fluid flow on the screen 1110 from either end may be from top-to-bottomas viewed in FIG. 41A, bottom-to-top, or from one side to the other.

In one aspect the screen 1116 is a scalping screen of woven steel mesh.In another aspect, it is woven plastic or synthetic or composite mesh;and in another aspect it is a combination of woven steel and wovenplastic or synthetic or composite mesh. The screen 1116 may be the samemesh or coarser mesh than that of the screen 1114 or of any layerthereof.

In this embodiment the areas 1117 between the screen 1116 and the screen1114 are open. The screen 1116 protects the mesh of the screen 1114 fromabrasive particles. When the screen 1116 is of a coarser mesh than thatof the screen 1114, relatively larger particles retained on the screen1116 are prevented from damaging and/or hindering flow through thescreen 1114.

With the screen 1110 as shown liquid flow through the screen isincreased by reducing the thickness of the solids bed of the finer meshscreens by the separation of larger particles with the screen 1116.

Use of the upper screen 1116 increases stability and rigidity of thescreen 1110, improving solids conveyance across and off, rather thanthrough the screen 1116 thereby facilitating liquid flow through thescreen. Solids that do not flow through the screen 1116 do not encounterthe lower finer mesh screens and do not reduce flow through the finermesh screens. Use of the upper screen 1116 also reduces the initialimpact load of flow onto the screen 1114 at a feed entrance to thescreen, thereby extending screen life.

FIG. 42 shows an alternative embodiment of the screen 1110 withidentical parts (indicated by the same numerals) but with additional endplugs 1119 between the upper screen 1116 and the screen 1114. Such“double plugging” may be used on either or both screen ends. A fluidand/or particles introduced to the screen 1110 first encounters thescreen 1116 and then material flowing through the screen 1116 flows tothe screen 1114. The plugs 1119 may be made of the materials describedfor the plugs 1113, 1115 and the plugs 1119 may be similarly installedand/or secured in place. Any of the plugs 1113, 1115, 1119 may bedeleted in certain embodiments.

FIG. 43 shows a screen 1120 like the screen 1110, but without thecushion members 1118. A scalping screen 1126 is secured at points 1127to a screen 1124 on a base, frame, or support 1122. The screens 1124,1126 may be in any of the forms discussed above for the screens 1114,1116, respectively and the base, frame, or support 1122 may have any ofthe forms or alternatives discussed above for the base, frame, orsupport 1112. The screen 1126 may be secured to the screen 1124 in anysuitable way, including but not limited to with glue, epoxy, fusedplastic and/or by welding and/or sintering.

FIG. 44A shows a screen 130 with a base, frame, or support 1132 on whichis a screen 1134 to which is secured a corrugated upper screen 1136 withoptional items 1138 (like the tape, cushion, strips 1118, above). In oneaspect the screens 1134 and 1136 are of different mesh; in one aspectwith coarser mesh in the screen 1136; and in another aspect the twoscreens are of a similar mesh. The screens 1134, 1136 may be like thescreens 1114, 1116 and 1124, 1126 respectively with respect to mesh sizeand materials. The base, frame, or support 1132 may be like the items1112, 1122 and their alternatives described above. As shown the screen1134 includes a fine mesh screen 1134 a on top of a coarser mesh screen1134 b. A third screen (not shown) of medium mesh (e.g. as in FIG. 41B)may be used. If used, the upper screen 1136 may be secured to or simplyrest on the items 1138 and the lower screen 1134 may be secured to orsimply rest beneath the items 1138. It is to be understood that theitems 1138 represent any of the strip(s), tape, etc. described aboveregarding the items 1118.

End plugs 1135 (FIGS. 44C, 44D) sealingly shut off the end openingsbeneath corrugations of the screen 1134. Open areas 1137 extend betweenthe screens 1134, 1136. Fluid flow on the screen 1130 may betop-to-bottom as viewed in FIG. 44A, bottom-to-top, or from one side toanother.

FIG. 44E shows an alternative embodiment of the screen 1130 with plugs1139 sealingly closing off the ends of the areas 1137 to fluid flow. Theplugs 1135, 1139 may be like, and installed as, any of the plugsdescribed above.

The screens in FIGS. 41A-44E have the advantages of an upper screen asdescribed for the screen 1110.

FIG. 40A discloses one example of a typical prior art shaker system(e.g. as shown in U.S. Pat. No. 5,190,645). FIG. 40B shows a system 1200according to the present invention with parts like those of the systemof FIG. 40A; but with a shale shaker K having a screen or screens Saccording to the present invention (any screen or screens disclosedherein). The screen(s) S are mounted in a typical shaker basket B andone or more vibrators V (any known suitable shaker vibrator) vibrate thebasket B and hence the screen(s) S.

The present invention, therefore, provides a screen assembly for avibratory separator, the screen assembly having at least one wire meshscreen formed with undulating mesh material having a series of ridgesspaced apart by a series of valleys, an optional corrugated perforatedplate with an undulating shape corresponding to the undulating meshmaterial of the at least one wire mesh screen, the at least one wiremesh screen on the corrugated perforated plate when it is used, andeither a series of spaced apart rods, the corrugated perforated platemounted on the rods of the series of spaced apart rods or lower coarsermesh screen. Such a screen assembly may have one, some, any combinationof, or all the following: wherein the at least one wire mesh screen isadhered to the corrugated perforated plate; wherein the at least onewire mesh screen is a plurality of two or more wire mesh screens;wherein the plurality of wire mesh screens are adhered together; whereinthe at least one wire mesh screen includes at least one upper wire meshscreen having a first mesh size and a lower wire mesh screen having amesh size coarser than the first screen mesh size; a pair of spacedapart top bars, one top bar on each side of the screen assembly at anouter edge of a side thereof; an adapter bar on which the corrugatedperforated plate is mounted, the adapter bar having recesses forreceiving the series of spaced-apart rods; a layer of seal material ontop of the adapter bar for sealing mounting thereon of the corrugatedperforated plate; the undulating shape of the at least one wire meshscreen and of the corrugated perforated plate forming a series of endopenings on two sides of the screen assembly, and plug apparatus in saidseries of end openings; and/or wherein said two sides with end openingsare encapsulated in encapsulating material.

The present invention discloses, in certain aspects, a screen assemblyfor a vibratory separator, the screen assembly having at least one wiremesh screen formed with undulating mesh material having a series ofridges spaced apart by a series of valleys, an optional corrugatedperforated plate with an undulating shape corresponding to theundulating mesh material of the at least one wire mesh screen, the atleast one wire mesh screen on the corrugated perforated plate, a seriesof spaced apart rods, the corrugated perforated plate mounted on therods of the series of spaced apart rods, and the rods having anundulating shape corresponding to the undulating shape of the undulatingmesh material of the at least one wire mesh screen. Such a screenassembly may have any of the features of the preceding paragraph in anycombination.

The present invention, in certain embodiments, discloses a support stripfor supporting part of a screen used in a vibratory shaker, the supportstrip with a support body having spaced-apart ends spaced-apart sides,and a top surface, and at least one upturned finger projecting above thetop surface of the support body, the at least one upturned fingerconfigured and sized for contacting and supporting at least a part of araised portion of the screen; such a support strip wherein the at leastone upturned finger is a plurality of spaced-apart upturned fingers;and/or wherein the at least one upturned finger has a curved top with ashape corresponding to a shape of a raised portion of the screen, and/orwherein the at least one upturned finger extends up from cuts in thesupport body and the at least one upturned finger is integral with thesupport body; and such a support strip with a support (totally internalor with part projecting from beneath the finger) beneath the at leastone upturned finger, and such a support strip wherein the internalsupport is secured to the at least one upturned finger, and such asupport strip wherein the internal support has a series of holestherethrough for fluid flow therethrough, and/or wherein the at leastone upturned finger defines an interior space, the internal support isdisposed within said interior space, and the internal support occupiesless than all said interior space, and/or wherein the interior space hasa top area, the internal support has a top surface, the top surface ofthe internal support is spaced apart from the at least one raised part,and the top surface of the internal support defining a lower limit ofthe top area, and/or wherein said support body has a body width and saidinternal support has a support width which is less than said body width,and/or wherein said support body has a series of holes therethrough forfluid flow therethrough; and/or any such support in combination with thescreen and/or in combination with a vibratory shaker on which the screenis releasably mounted.

The present invention, in certain embodiments discloses a support stripfor supporting part of a screen used in a vibratory shaker, the supportstrip having a support body having spaced-apart ends spaced-apart sides,and a top surface, and at least one raised portion projecting above thetop surface of the support body, the at least one raised portionconfigured and sized for contacting and supporting at least a part of araised portion of the screen of a support and/or with a support beneaththe raised portion(s), including any embodiment described in thepreceding paragraph.

The present invention, in certain embodiments, discloses a screenapparatus for a vibratory shaker device, the screen apparatus withscreening material with an undulating shape with a series of raisedportions, and at least one support strip beneath said screening materialand in contact therewith, said at least one support strip between onehalf inch to three inches in width and between one thirty-second of aninch and one-eighth of an inch in thickness, said at least one supportstrip having at least one raised part thereof with a shape correspondingto a shape of a raised portion of the screening material, said at leastone raised part positioned beneath and supporting said raised portion,and the at least one raised part thereof having a support thereunder.

The present invention discloses, in certain embodiments, a separatoryapparatus with a vibratory shaker device, a screen apparatus mounted onthe vibratory shaker device and with screening material with anundulating shape with a series of raised portions, and at least onesupport strip beneath said screening material and in contact therewith,said at least one support strip between one half inch to three inches inwidth and between one thirty-second of an inch and one-eighth of an inchin thickness, said at least one support strip having at least one raisedpart thereof with a shape corresponding to a shape of a raised portionof the screening material, said at least one part positioned beneath andsupporting said raised portion, and the at least one raised part thereofhaving a support thereunder.

The present invention discloses, in certain embodiments, a screenassembly for screening material in a vibratory screening machine, saidassembly with a frame, a plurality of apertures in said frame, spacedframe members on opposite sides of said plurality of apertures, a screenformed in an undulating shape with elongated substantially parallelridges having sloping sides, troughs formed between said sloping sidesfor conducting material which is being screened longitudinally of saidtroughs while it is being screened, undersides on said troughs, saidundersides of said troughs being secured to said spaced frame members onthe opposite sides of a plurality of said apertures with said ridges andtroughs overlying said plurality of apertures, said elongated ridgeshaving first end portions, said troughs having second end portions, andsealing means for sealing said first end portions of said elongatedridges against entry of material which is being screened whilemaintaining said second end portions unsealed to permit passage of saidmaterial being screened therethrough, and at least one support beneathat least one of said ridges.

The present invention discloses, in certain embodiments, a plurality ofscreen assemblies for mounting on a vibratory screening machine forscreening material, each assembly with a plate, a plurality of aperturesin said plate, elongated spaced plate members on opposite sides of saidplurality of apertures, a screen formed in an undulating shape withelongated substantially parallel ridges, troughs formed between saidridges of each of said screen assemblies for conducting materiallongitudinally of said troughs while it is being screened, andundersides on said troughs, said undersides of said troughs beingsecured to said elongated spaced plate members on the opposite sides ofa plurality of said apertures, each screen assembly being mountedadjacent to another screen assembly with said ridges and troughs ofadjacent assemblies being in alignment so that material which is beingscreened can pass longitudinally through the aligned troughs of saidadjacent screen assemblies, and at least one support beneath at leastone of said ridges.

The present invention discloses, in certain embodiments, a plurality ofscreen assemblies for mounting on a vibratory screening machine forscreening material, each assembly with a frame, a plurality of aperturesin said frame, elongated spaced frame members on opposite sides of saidplurality of apertures, a screen formed in an undulating shape withelongated substantially parallel ridges, troughs formed between saidridges of each of said screen assemblies for conducting material whichis being screened longitudinally of said troughs while it is beingscreened, and undersides on said troughs, said undersides of saidtroughs being secured to said spaced frame members on the opposite sidesof a plurality of said apertures with said ridges over-lying saidplurality of apertures, each assembly being mounted adjacent to anotherscreen assembly with said ridges and troughs of adjacent assembliesbeing in alignment so that material which is being screened can passlongitudinally through the aligned troughs of said adjacent screenassemblies, and at least one support beneath at least one of saidridges.

The present invention discloses, in certain embodiments, a screenassembly for screening material in a vibratory screening machine, saidassembly with a plate having a length and a width, an area defined bysaid length and width, a plurality of plate members on said plate, aplurality of apertures defined by said plate members, a multiple-layerscreen formed in an undulating shape to provide a screening area whichis larger than said area of said plate, said multiple layer screenincluding a plurality of elongated alternating parallel ridges andtroughs, said ridges further including side walls extending toward saidplate and defining said troughs for conducting material which is beingscreened longitudinally of said troughs while it is being screened,undersides on said plurality of troughs, said undersides of saidplurality of troughs being secured to said plate members where saidundersides of said troughs overlie said plate members, said plurality ofridges which comprise said screening area which is larger than the areaof said plate overlying said plurality of apertures, said screencomprising an undulating screening screen and an apertured plate formedin the same undulating shape as said screening screen and located inunderlying relationship thereto and secured to said plate, saidelongated ridges having first end portions which are sealed againstentry of material which is being screened, and said troughs havingsecond end portions which are unsealed, and at least one support beneathat least one of said ridges.

The present invention discloses, in certain embodiments, a screenassembly for screening material in a vibratory screening machine, saidassembly with a plate having a length and a width, an area defined bysaid length and width, a plurality of plate members on said plate, aplurality of apertures defined by said plate members, a multiple-layerscreen formed in an undulating shape to provide a screening area whichis larger than said area of said plate, said multiple layer screenincluding a plurality of elongated alternating parallel ridges andtroughs, said ridges further including side walls extending toward saidplate and defining said troughs for conducting material which is beingscreened longitudinally of said troughs while it is being screened,undersides on said plurality of troughs, said undersides of saidplurality of troughs being secured to said plate members where saidundersides of said troughs overlie said plate members, said plurality ofridges which comprise said screening area which is larger than the areaof said plate overlying said plurality of apertures, said elongatedridges have first end portions which are sealed against entry ofmaterial which is being screened, and said troughs have second endportions which are unsealed, and at least one support beneath at leastone of said ridges.

The present invention discloses, in certain embodiments a screenassembly for screening material in a vibratory screening machine, saidassembly with a plate having a length and a width, an area defined bysaid length and width, a plurality of plate members on said plate, aplurality of apertures defined by said plate members, a multiple-layerscreen formed in an undulating shape to provide a screening area whichis larger than said area of said plate, said multiple layer screenincluding a plurality of elongated alternating parallel ridges andtroughs, said ridges further including side walls extending toward saidplate and defining said troughs for conducting material which is beingscreened longitudinally of said troughs while it is being screened,undersides on said plurality of troughs, said undersides of saidplurality of troughs being secured to said plate members where saidundersides of said trough overlie said plate members, said plurality ofridges which comprise said screening area which is larger than the areaof said plate overlying said plurality of apertures, said screencomprising an undulating base screen of relatively large mesh, anundulating top screening screen of fine mesh, and an undulatingintermediate screening screen of less fine mesh than said top screen,said intermediate screen being located between said base screen and saidtop screen, said elongated ridges have first end portions which aresealed against entry of material which is being screened, and saidtroughs have second end portions which are unsealed, and at least onesupport beneath at least one of said ridges.

The present invention discloses, in certain embodiments, a screenassembly for screening material in a vibratory screening machine with anundulating apertured plate having ridges and troughs between saidridges, and a screen formed in the same configuration as said aperturedplate and bonded in complementary mating relationship thereto, open endson said ridges and said troughs, and means for sealing said open ends ofsaid ridges while permitting said open ends of said troughs to remainunsealed, and at least one support beneath at least one of said ridges.

The present invention discloses, in certain embodiments, a screen forscreening material in a vibratory screening machine comprising a coarsescreen and a fine screen bonded thereto, said fine and coarse screensbeing formed into an undulating shape having substantially parallelridges and troughs between said ridges for conducting material beingscreened in a direction longitudinally of said troughs while saidmaterial is being screened, said ridges having first ends, seals sealingsaid first ends of said ridges, and said troughs having second endswhile are unsealed, and at least one support beneath at least one ofsaid ridges.

In conclusion, therefore, it is seen that the present invention and theembodiments disclosed herein and those covered by the appended claimsare well adapted to carry out the objectives and obtain the ends setforth. Certain changes can be made in the subject matter withoutdeparting from the spirit and the scope of this invention. It isrealized that changes are possible within the scope of this inventionand it is further intended that each element or step recited in any ofthe following claims is to be understood as referring to all equivalentelements or steps. The following claims are intended to cover theinvention as broadly as legally possible in whatever form it may beutilized. The invention claimed herein is new and novel in accordancewith 35 U.S.C. §102 and satisfies the conditions for patentability in§102. The invention claimed herein is not obvious in accordance with 35U.S.C. §103 and satisfies the conditions for patentability in §103. Thisspecification and the claims that follow are in accordance with all ofthe requirements of 35 U.S.C. §112. The inventors may rely on theDoctrine of Equivalents to determine and assess the scope of theirinvention and of the claims that follow as they may pertain to apparatusnot materially departing from, but outside of, the literal scope of theinvention as set forth in the following claims.

What is claimed is:
 1. A screen assembly for a vibratory separator, thescreen assembly comprising at least one wire mesh screen formed withundulating mesh material having a series of ridges spaced apart by aseries of valleys, a corrugated perforated plate with an undulatingshape corresponding to the undulating mesh material of the at least onewire mesh screen, the corrugated perforated plate having a first sideand a second side spaced apart from the first side, the at least onewire mesh screen on the corrugated perforated plate, and a series ofspaced apart rods all of which are in one plane, the corrugatedperforated plate mounted on the rods of the series of spaced apart rods,each of the spaced apart rods extending from the first side of thecorrugated perforated plate to the second side thereof, and each rodindependent of and not connected to the other rods between the first andsecond sides of the corrugated perforated plate, each rod having twospaced apart ends.
 2. The screen assembly of claim 1 wherein the atleast one wire mesh screen is adhered to the corrugated perforatedplate.
 3. The screen assembly of claim 1 wherein the at least one wiremesh screen is a plurality of two or more wire mesh screens.
 4. Thescreen assembly of claim 3 wherein the plurality of wire mesh screensare adhered together.
 5. The screen assembly of claim 1 wherein the atleast one wire mesh screen includes at least one upper wire mesh screenhaving a first mesh size and a lower wire mesh screen having a mesh sizecoarser than the first screen mesh size.
 6. The screen assembly of claim1 further comprising a pair of spaced apart top bars, one top bar oneach side of the screen assembly at an outer edge of a side thereof. 7.The screen assembly of claim 1 further comprising an adapter bar onwhich the corrugated perforated plate is mounted, the adapter bar havingrecesses for receiving the series of spaced-apart rods.
 8. The screenassembly of claim 7 further comprising a layer of seal material on topof the adapter bar for sealing mounting thereon of the corrugatedperforated plate.
 9. The screen assembly of claim 1 further comprisingthe undulating shape of the at least one wire mesh screen and of thecorrugated perforated plate forming a series of end openings on twosides of the screen assembly, and plug apparatus in said series of endopenings.
 10. The screen assembly of claim 9 wherein said two sides withend openings are encapsulated in encapsulating material.
 11. A screenassembly for a vibratory separator, the screen assembly comprising atleast one wire mesh screen formed with undulating mesh material having aseries of ridges spaced apart by a series of valleys, a corrugatedperforated plate with an undulating shape corresponding to theundulating mesh material of the at least one wire mesh screen, thecorrugated perforated plate having a first side and a second side spacedapart from the first side, the at least one wire mesh screen on thecorrugated perforated plate, and a series of spaced apart rods all ofwhich are in one plane, the corrugated perforated plate mounted on therods of the series of spaced apart rods, each of the spaced apart rodsextending from the first side of the corrugated perforated plate to thesecond side thereof, each rod independent of and not connected to theother rods between the first and second sides of the corrugatedperforated plate, each rod having two spaced apart ends, wherein the atleast one wire mesh screen is adhered to the corrugated perforatedplate, wherein the at least one wire mesh screen is a plurality of twoor more wire mesh screens, wherein the plurality of wire mesh screensare adhered together, wherein the at least one wire mesh screen includesat least one upper wire mesh screen having a first mesh size and a lowerwire mesh screen having a mesh size coarser than the first screen meshsize, a pair of spaced apart top bars, one top bar on each side of thescreen assembly at an outer edge of a side thereof, the undulating shapeof the at least one wire mesh screen and of the corrugated perforatedplate forming a series of end openings on two sides of the screenassembly, and plug apparatus in said series of end openings.
 12. Ascreen assembly for a vibratory separator, the screen assemblycomprising at least one wire mesh screen formed with undulating meshmaterial having a series of ridges spaced apart by a series of valleys,the at least one wire mesh screen on a corrugated perforated plate, thecorrugated perforated plate having a first side and a second side spacedapart from the first side,and a series of spaced apart rods all of whichare in one plane, the corrugated perforated plate mounted an the rods ofthe series of spaced apart rods, each of the spaced apart rods extendingfrom the first side of the corrugated perforated plate to the secondside thereof, and each rod independent of and not connected to the otherrods between the first and second sides of the corrugated perforatedplate, each rod having two spaced apart ends.
 13. A screen assembly fora vibratory separator, the screen assembly comprising at least one wiremesh screen formed with undulating mesh material having a series ofridges spaced apart by a series of valleys, a corrugated perforatedplate with an undulating shape corresponding to the undulating meshmaterial of the at least one wire mesh screen, the corrugated perforatedplate having a first side and a second side spaced apart from the firstside, the at least one wire mesh screen on the corrugated perforatedplate, and a series of spaced apart rods all of which are in one planes,the corrugated perforated plate mounted on the rods of the series ofspaced apart rods, each of the spaced apart rods extending from thefirst side of the corrugated perforated plate to the second sidethereof, each rod independent of and not connected to the other rodsbetween the first and second sides of the corrugated perforated plate,each rod having two spaced apart ends and the rods having an undulatingshape corresponding to the undulating shape of the undulating meshmaterial of the at least one wire mesh screen.
 14. The screen assemblyof claim 13 wherein the at least one wire mesh screen has opposedspaced-apart front and rear edges encapsulated in encapsulatingmaterial.
 15. The screen assembly of claim 13 wherein the at least onewire mesh screen is adhered to the corrugated perforated plate.
 16. Thescreen assembly of claim 13 wherein the at least one wire mesh screen isa plurality of two or more wire mesh screens.
 17. The screen assembly ofclaim 16 wherein the plurality of wire mesh screens are adheredtogether.
 18. The screen assembly of claim 13 further comprising a pairof spaced apart top bars, one top bar on each side of the screenassembly at an outer edge of a side thereof.
 19. The screen assembly ofclaim 13 further comprising an adapter bar on which the corrugatedperforated plate Is mounted, the adapter bar having recesses forreceiving the series of spaced-apart rods.
 20. The screen assembly ofclaim 19 further comprising a layer of seal material on top of theadapter bar for sealing mounting thereon of the corrugated perforatedplate.
 21. The screen assembly of claim 13 further comprising theundulating shape of the at least one wire mesh screen and of thecorrugated perforated plate forming a series of end openings on twosides of the screen assembly, and plug apparatus in said series of endopenings.
 22. The screen assembly of claim 21 wherein said two sideswith end openings are encapsulated in encapsulating material.